Yamaha XS850G Owner's Manual
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Yamaha XS850G Owner's Manual

Yamaha XS850G Owner's Manual

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  • Page 2 XS850G OWNER’S MANUAL 1ST PRINTING, JULY 1979 ALL RIGHTS RESERVED, BY YAMAHA MOTOR COMPANY LIMITED, JAPAN PRINTED IN JAPAN P/N LIT-l 1626-01-79...
  • Page 3 PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE. DO NOT ATTEMPT TO OPERATE THIS MOTORCYCLE UNTIL YOU HAVE ATTAINED A SATISFACTORY KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES AND HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES. REGULAR INSPECTIONS AND CAREFUL MAINTENANCE ARE REQUIRED IN ADDITION TO RIDING SKILL IN ORDER TO ENJOY THE CAPABILITIES AND RELIABILITY OF THIS MOTOR-...
  • Page 4 NOTE: This manual should be considered a permanent part of this motorcycle and should remain with it even if the motorcycle is subsequently sold. -SAFETY WARNINGS: 1, Traffic regulations vary from state to state. Study the regulations in your state before riding this motorcycle. 2.
  • Page 5 Always turn off the engine before leaving the motorcycle unat- tended and do not forget to remove the ignition key. When park- ing the motorcycle, note the following: The engine and exhaust pipe(s)/muffler(s) may be hot. Park the motorcycle in a place where pedestrians or children are not like- ly to touch the motorcycle.
  • Page 6 Congratulations on your purchase of the this model in the future. If there is any Yamaha XS850G. This model represents the question concerning this manual, con- product of many years of Yamaha experience sult your nearby Yamaha dealer.
  • Page 7 CONTENTS LOCATION OF THE “CAUTION AND SPECIFICATION LABELS” ,.,.,....... 1 DESCRIPTION ..,,,...........~ 2 MACHINE I D E N T I F I C A T I O N CONTROL F PRE-OPERATION CHECKS ..,,...... 15 OPERATION AND IMPORTANT RIDING POINTS PERIODIC MAINTENANCE AND MINOR REPAIR .,..,,,,,,.,..,.,.,......
  • Page 9 DESCRIPTION RIGHT SIDE LEFT SIDE INSTRUMENTS...
  • Page 10 Keep a record of these numbers for reference when ordering parts from Your Yamaha deal- Engine serial number er. In case of theft, the authorities will need...
  • Page 11 With the lever in this position fuel position, and then switch to the “ON” flows if the engine is running but stops position after starting the engine. if the engine is not running. RES: This indicates “RESERVE”. If you run Starter (CHOKE) out of fuel while riding, move the lever When cold, the engine requires a richer fuel...
  • Page 12 Seat lock To open the seat lock insert the key in the lock and turn it counterclockwise and pull the Steering lock lever backwards. To lock the steering, turn the handlebars fully to the right, insert the key into the steering lock and turn the key about l/8 turn coun- terclockwise.
  • Page 13 In reinstalling the seat. insert the lobes on the seat front into the receptacles on the Never ride with a helmet in the helmet frame, then push down the seat at the end. holder. It could interfere with rear wheel After making sure the seat is securely fitted, movement, causing loss of control and turn the key clockwise to the center position...
  • Page 14 Front forks The front forks of this model are pneumome- chanical; namely, a combination air and me- chanical coil spring in the inner tube provides suspension best suited to the motorcycle’s load (ex: optional accessories etc.) and riding conditions by the adjustment of the air pres- sure.
  • Page 15 Please ask your nearby Yamaha dealer for further details. Kick starter To start the engine. rotate the kick crank. push down lightly with foot until gears engage, and then kick forcefully. This model cannot be started unless the transmission is in neutral.
  • Page 16 PRE-OPERATION CHECKS (DAILY) Before using this motorcycle check the following points: Item Routine Page Check operation, free play and fluid. Brakes (Front and Rear) Top-up with DOT. #3 brake fluid 1 6 . 4 4 if necessary. Check operation. condition and free play. 2.
  • Page 17 Do not operate the they are working properly. Check the motorcycle until the failure in the brake system is corrected. Ask your Yamaha brakes at low speed shortly after start- dealer or other qualified mechanic for ing out.
  • Page 18 leakage could indicate a hazardous con- dition in the brake system. Clutch (See page 49 for more detail) Check for correct play in the clutch lever and make sure the lever operates properly. If the play is incorrect, make an adjustment, Throttle grip (See page 50 for more detail) Turn the throttle grip to see if it operates properly and if the play is normal.
  • Page 19 If desired, an SAE 80W/90 hypoid gear oil Recommended oil: may be used for all conditions. NOTE: “GL-4” is a quality and additive rating. “GL- 5” or “GL-6” rated hypoid gear oils may also be used. Middle gear/Final gear oil (See page 40 for more detail) T U B E L E S S T I R E S A N D A L U M I N U M Make sure the middle gear/final gear oil is at...
  • Page 20 Tubeless-type Wheel --t Tube-type When using tube-type tires be sure to install the proper tube also. To insure maximum performance, long ser- vice, and safe operation, note the following precautions: Always maintain proper air pressure as described in the Chart on page 21. Check tire pressure.
  • Page 21 The standard equipment tires originally fitted be replaced. to the XS850G are suited to normal riding 5. Tires and wheels should be balanced and touring. They are not suited for sustained whenever either one is changed or re- high speed running or racing and must not be placed.
  • Page 22 Yamaha has a full line of sport and touring accessories designed specifically for this motor- cycle. Please consider them before making a purchase.
  • Page 23 Yamaha Service Technician or other qualified mechanic. If you must change your own tire, be sure to use proper tools and procedures as described in the Tubeless Tire and Wheel Manual available from Your Yamaha dealer.
  • Page 24 Switches Check the operation of the headlight switch, turn switch, brake light switch, horn button, main switch, etc. Battery (See page 58 for more detail) Check fluid level and top-up if necessary. Use only distilled water if refilling is neces- sary.
  • Page 25 Before starting out, always be sure operating controls and their func- the side stand is up. Failure to re- tion. Consult your Yamaha dealer or tract the side stand completely can other qualified mechanic regarding result in a serious accident when any control or function you do not you try to turn a corner.
  • Page 26 If the light does not go off even with sufficient oil in the crankcase, consult NOTE: your Yamaha dealer or other qualified If the engine fails to start, release the starter mechanic. button, then push the starter button again.
  • Page 27 7. After warming up the engine, turn off Starting a warm engine the starter (push back the starter com- To start a warm engine, the starter (CHOKE) pletely). is not required. Engine break-in There is never a more important period in the life of your motorcycle than the period between zero and 1,000 km (600 mi).
  • Page 28 If any engine trouble should occur dur- Allow a cooling off period of 5 to 10 ing the break-in period, consult your Yamaha dealer immediately or other minutes after every hour of operation. Vary the speed of the motorcycle from qualified mechanic.
  • Page 29 To start out and accelerate: To decelerate: Pull the clutch lever to disengage the Apply front and/or rear brakes to slow clutch. the motorcycle. Shift into FIRST gear. The green neutral When the motorcycle reaches 20 km/h indicator light should go out. (12.5 mi/h), shift to first gear.
  • Page 30 - W A R N I N G : C A U T I O N : Select a parking place where the motor- 1. Do not glide for long periods with cycle is not apt to fall. Do not park the the engine off, and do not tow the motorcycle a long distance.

  • Page 31: Minor Repair

    SPECIALIZED DATA, KNOWLEDGE, AND certified (if applicable).” EQUIPMENT. YAMAHA DEALERS ARE TRAINED AND EQUIPPED TO PERFORM THESE PARTICULAR SERVICES. I f t h e o w n e r i s n o t f a m i l i a r w i t h d o n e b y a Y a m a h a d e a l e r o r o t h e r qualified mechanic.
  • Page 32 The service information included in this during a service operation requiring one, take manual is intended to provide you, the owner. your motorcycle to a Yamaha dealer or other with the necessary information for complet- qualified mechanic to check the torque set- ing some of your own preventive mainten- tings and adjust them as necessary.
  • Page 33 Check for leakage. Retighten as necessary. Replace gasket(s) if necessary. Adjust synchronization of carburetors. synchronization Check and adjust engine idle speed. Adjust cable free play if necessary. recommended that these items be serviced by your Yamaha dealer or other qualified mechanic...
  • Page 34 I n s t e a d . t a k e t h e spark plug properly. motorcycle to your Yamaha dealer or other qualified mechanic. You should periodically remove and inspect...
  • Page 35 NOTE: If a torque wrench not available when you are installing a spark plug. a good estimate of the correct torque is l/4 to l/2 turns past finger tights. Have the spark plug torqued to the correct value as soon as possible with a torque wrench.
  • Page 36 Adjust free play 5 * Brake Replace pads system if necessary Clutch Adjust free play Yamaha chain and Apply chain lube 7* Control and cable lube or meter cable thoroughly 1 0W/30 motor oil Check bearings assembly for...
  • Page 37 16,000 km (10,000 mi) Check bearings for smooth rotation. bearings Replace if necessary Check specific gravity. Check Battery breather pipe for proper operation It is recommended that these items be serviced by your Yamaha dealer or other qualified mechanic. -36-...

  • Page 38: Torque Specifications

    Torque specifications (For a more complete list, refer to the Service checked occasionally, especially before a Manual for this model.) long trip. Always check the tightness of Use a torque wrench to tighten these items. It these items whenever they are loosened for is recommended that these items should be any reason.
  • Page 39 Engine oil 1. Oil level measurement a. Place the motorcycle on the center stand. Warm up the engine for several minutes. NOTE: Be sure the motorcycle is positioned straight up when checking the oil level; a slight tilt toward the side can produce false readings. b.
  • Page 40 e. Re-install the drain plug (make sure it is tight). Drain plug torque: 4.3 m-kg (31 .O ft-lb) f. Install the new oil filter element. new “O” ring and filter cover, tighten the oil filter bolt. Oil filter bolt: 3.2 m-kg (23.0 ft-lb) d.
  • Page 41 g. Add oil through the oil filler hole. With oil filter replacement: Recommended oil: See page 17. Middle gear/Final gear oil Oil level measurement Place the motorcycle on a level place and place it on the center stand. The engine should be cool (at atmospheric temperature).
  • Page 42 NOTE: Middle gear and final gear oil can be checked Take care not to allow foreign material with same level gauge, which is in the owners tool kit. 2. Gear oil replacement a. Place an oil pan under the transmission for the middle gear and under the final gear case.
  • Page 43 d. Fill the gear case(s) to the specified c. Reinstall and tighten the middle and/or final gear drain plug(s). (See page 37 for torque specifications.) Oil capacity: Middle gear case: Approx. 0.375 lit (0.40 US qt) Final gear case: Approx. 0.30 lit (0.32 US qt) Recommended oil: See page 18.
  • Page 44 2. Cleaning method Tap the element lightly to remove most of the dust and dirt; then blow out the remaining dirt with compressed air from the inner surface of the element. If ele- ment is damaged, replace it. b. Pull out the element. 3.
  • Page 45 NOTE: is operated. Air in the system will result Check for correct play and make sure it is in greatly diminished braking capability working properly. and can result in loss of control and an accident. Have your Yamaha dealer or...
  • Page 46 - C A U T I O N : For the brake pedal position adjust- ment, be sure to proceed as follows; (It is advisable to have your Yamaha dealer or other qualified mechanic make this adjustment.) 6. Pedal height 20 mm 10.78 an, The rear brake pedal should be so adjusted 2.
  • Page 47 To check, open the wear indicator cap. If any 3. Secure the adjuster lock nut. pad is worn to the red line, ask a Yamaha 4. Loosen the brake rod downward until dealer or other qualified mechanic to replace there is noticeable free play between the pads.
  • Page 48 Inspecting the brake fluid level Insufficient brake fluid may allow air to enter the ‘brake system, possibly causing the brakes to become ineffective. Before riding, check the brake fluid level and replenish when necessary. and observe these precautions: 1, Use only the designated quality brake fluid;...
  • Page 49 Have a Yamaha dealer or other qualified Proper adjustment is achieved when the mechanic check the cause if the brake brake light comes on slightly before the fluid level goes down.
  • Page 50 Clutch adjustment This model has a clutch cable length adjuster and a clutch mechanism adjuster. The cable length adjuster is used to take up slack from cable stretch and to provide sufficient free play for proper clutch operation under vari- ous operating conditions.
  • Page 51 This adjustment must be checked be- ed. An unsafe condition may result, cause heat and clutch wear will affect replace such cables as soon as possible. this free play, possibly enough to cause 2. If the inner cables do not operate incomplete clutch operation.
  • Page 52 Rear arm pivot bearings The swing arm must pivot freely on its bear- ings but not have any excess play. Have your Yamaha dealer or other qualified mechanic check rear arm pivot bearing operation ac- cording to the General Maintenance Sched- ule.
  • Page 53 The spring seat and fork spring are re- tained by a stopper ring (spring wire circlip). It is necessary to depress the spring seat and fork spring to remove the stopper ring. Remove the stopper ring by carefully prying out one end with a small screwdriver.
  • Page 54 Inspect the drain screw gasket. Replace if damaged. Reinstall the drain screw. Pour the specified amount of oil into the fork inner tube. Front fork oil (each fork): 195 cc (6.60 oz) Yamaha Fork Oil 10 wt or equivalent...
  • Page 55 Reinstall the spring seat and fill the fork NOTE: with air using a manual air pump or When checking and adjusting the air pres- other pressurized air supply. Refer to sure, there should be no weight on the front “Front fork and rear shock absorber ad- end of the motorcycle.
  • Page 56 4. Install the rubber caps securely. Rear shock absorber: 1, Spring preload If the spring seat is raised, the spring becomes stiffer and if lowered, it be- comes softer. Standard position - A A. position - Softest E. position - Stiffest Standard air pressure: 0.4 kg/cm* (5.7 psi) Maximum air pressure:...
  • Page 57 2. Damping force Turn the damping force adjuster with your fingers to increase or decrease the damping force. If it is difficult to turn it with your fingers. use a screw driver. NOTE: When adjusting the damping force, the ad- juster should be placed in the clicked posi- tion.
  • Page 58 Periodically inspect the condition of the try to move it forward and backward. If any steering. Worn out or loose steering bearings free play can be felt, ask a Yamaha dealer or other qualified mechanic to inspect and ad- may be dangerous.
  • Page 59 Keep sparks, flame, cigarettes, etc. wheel does not turn smoothly, have your away. Ventilate when charging or using Yamaha dealer or a qualified mechanic in- in closed space. Always shield eyes spect the wheel bearings. The wheel bear- when working near batteries. KEEP ings should be inspected according to the OUT OF REACH OF CHILDREN.
  • Page 60 Replenishing the battery fluid When the motorcycle is not to be used for a month or longer, remove the bat- A poorly maintained battery will deteriorate tery and store it in a cool, dark place. quickly. The battery fluid should be checked Completely recharge the battery before at least once a month.
  • Page 61 Headlight This motorcycle is equipped with a quartz bulb headlight. If the headlight bulb burns out. replace the bulb as follows: 1. Headlight bulb replacement a. Remove the 2 screws holding the light unit assembly to the headlight body. c. Turn the bulb holder counterclockwise and remove the defective bulb.
  • Page 62 d. Slip a new bulb into position and secure it with the bulb holder - C A U T I O N : 1. Avoid touching the glass part of the bulb. Also keep it free from oil stains; otherwise, the transparency of the glass, life of the bulb and il- luminous flux will be adversely af- fected.
  • Page 63 Fuse replacement 1. The fuse block is located under the seat. b. Vertical adjustment: 2. If any fuse is blown, turn off the ignition 1 ) Loosen the adjusting screw under the switch and the switch in the circuit in headlight body.
  • Page 64 3. Remove the cotter pin and wheel axle - W A R N I N G : nut. Do not use fuses of a higher amperage rating than those recommended. Sub- stitution of a fuse of improper rating can cause extensive electrical system dam- age and possible fire.
  • Page 65 7. During reassembly, check the following: a. Make sure the projecting portion (torque stopper) of the speedometer housing is positioned correctly. 6. Lower the wheel until the discs come off the calipers. Turn the calipers out- ward so they do not obstruct the wheel and remove the wheel.
  • Page 66 d. Before tightening the holder nuts, stroke the front forks several times to make sure of proper fork operation. With the axle holder nuts loose, work the left fork leg back and forth until the proper clearance between the disc and caliper bracket are obtained.
  • Page 67 With the wire tool in this position, place Hook one end of the wire tool (contain- the motorcycle on the center stand. ed in the owner’s tool kit) to the hook Remove the seat and unscrew the rear attached to the frame. fender installation bolts until their Apply your weight to the rear part of the threaded portion is completely out.
  • Page 68 8. While supporting the brake caliper, pull out the rear axle. 7. Loosen the rear axle pinch bolt. Pull out the rear brake torque stopper plate from where it is retained rear arm. Next, suspend the caliper as- sembly with the big end of the wire tool (contained in the owner’s tool kit) hang- ing on the rear stay and the small end on the metal area of the brake caliper...
  • Page 69 10. Move the wheel to the right side to separate it from the final gear case and remove the rear wheel. NOTE: Do not depress the brake pedal when the wheel is off the motorcycle as the brake pads will be forced to shut. 1.
  • Page 70 The carburetor is a vital part of the en- gine and its emission control system. Adjusting should be left to your Yamaha dealer or other qualified mechanic with the professional knowledge, specialized data and equipment to do so properly.
  • Page 71 For replacement parts, Yamaha recommends you use Genuine Yamaha Parts, or parts you know are equiva- lent in quality. Any problem in the fuel, compression or igni- tion system can cause poor starting, exces- sive emissions, engine damage, or loss of power while riding.

  • Page 73: Consumer Information

    The information presented represents results obtainable by skilled drivers under controlled road and vehicle conditions and the information may not be correct under other conditions. Description of vehicles to which this table apples. Yamaha motorcycle XS850G L o a d A.
  • Page 74 Description of vehicles to which this table applies Yamaha motorcycle XS850G Summary table Low-speed p a s s ........3 5 1 feet: 7.1 seconds H i g h - s p e e d p a s s ,,.,,....

  • Page 75: Cleaning And Storage

    contamination of wheel bearings, front CLEANING AND forks, brake calipers, and transmission STORAGE seals. Many expensive repair bills have resulted from improper use of high pres- sure detergent applications such as A. CLEANING those available in coin-operated car Frequent thorough cleaning of your motor- washes.
  • Page 76 8. Automotive-type wax may be applied to 3. Remove the spark plug. pour about one all painted and chrome-plated surfaces. t a b l e s p o o n o f 10W/30 o r 2 0 W / 4 0 Avoid combination cleaner-waxes.
  • Page 77 month, Do not store the battery in an excessively warm or cold place (less than 0°C (32°F) or more than 30°C (86°F)). NOTE: Make any necessary repairs before storing the motorcycle.

  • Page 78: General Specifications

    SPECIFI CATIONS General specifications XS850G M O D E L Dimension: Overall length 2,175 mm (85.6 in) Overall width 900 mm (35 .4 in) Overall height 1,190 mm (46.9 in) Wheelbase 1,450 mm (57.1 Mlnlmum road clearance 140 mm / ( 5.5 in)
  • Page 79 M O D E L XS850G Ignition system Battery ignition (Full transistor ignition) Fuel tank capacity Total: 17 lit (4.5 US gal) Reserve: 3 lit (0.8 US gal) Engine oil quantity Total amount: 3.7 lit (3.91 US qt) Periodic oil change: 2.8 lit (2.96 US qt)
  • Page 80 M O D E L XS850G Chassis: Tubular. double-cradle Frame type Steering: Caster 131 mm (5.16 in) Trail Tire size: 3.25H 19-4PR Front 4.50H 17-4PR Rear Disc brake/Right hand operation Braking system: Front Disc brake/Right foot operation Rear Telescopic fork (Pneumo-mechanical)

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